H2O
INDIRECT-FIRED
WATER HEATERS
FOR SINGLE WATER HEATER
INSTALLATIONS
INSTALLATION, OPERATION &
MAINTENANCE MANUAL
30, 40, 50, 60, 80, 85, 115
Gallon
L = Low Boy Profile
C = Commercial Pipe
Connections
HO = High Output
XHO = Extra High Output
Conforms to UL STD 174
Certified to CAN/CSA STD C22.2 No. 110-94
ECR International, Inc.
2201 Dwyer Avenue, Utica NY 13501
Information and specifications outlined in this manual in effect at the
time of printing of this manual. ECR International, Inc. reserves the
right to discontinue, change specifications or system design at any time
without notice and without incurring any obligation, whatsoever.
web site: www.ecrinternational.com
An ISO 9001-2008 Certified Company
P/N# 615000054, Rev. C [12/2014]
MODELS
H2OI30
H2OI40
H2OI40L
H2OI50
H2OI60
H2OI60HO
H2OI60L
H2OI80
H2OI80HO
H2OI80HOC
H2OI85XHOC
H2OI115
H2OI115HO
H2OI115HOC
H2OI115XHOC
Table of Contents
I.
General Information................................................................................................................ 3
II.
Pre-installation Considerations................................................................................................. 5
III. Piping..................................................................................................................................11
IV.
Electrical..............................................................................................................................15
V.
Operation.............................................................................................................................15
VI. Maintenance.........................................................................................................................20
VII. Troubleshooting....................................................................................................................22
SAVE THESE INSTRUCTIONS
Hazard Definitions
The following defined terms are used throughout this manual to bring attention to the presence
of hazards or various risk levels or to important information concerning the life of the product.
! DANGER
Indicates a presence of hazards that WILL cause severe personal injury,
death or substantial property damage.
! WARNING
Indicates a presence of hazards that CAN cause severe personal injury,
death or substantial property damage.
! CAUTION
Indicates a presence of hazards that will or can cause minor
personal injury, or property damage.
NOTICE
Indicates special instructions on installation, operation or
maintenance that are important but not related to personal injury
or property damage.
2
I. General Information
IMPORTANT INFORMATION – READ CAREFULLY
NOTE: The equipment shall be installed in accordance with those installation regulations required in the area where the
installation is to be made. These regulations shall be carefully followed in all cases. Authorities having jurisdiction shall be
consulted before installations are made.
All wiring on water heaters shall be in accordance with the National Electrical Code and/or local regulations.
! WARNING
Improper installation, adjustment, alteration, service or maintenance can cause property damage, personal injury, or loss
of life. Read and understand the entire manual before attempting installation, start-up, operation, or service. Installation
and service must be performed only by an experienced, skilled installer or service agency.
This water heater contains very hot water under high pressure. Do not unscrew any pipe fittings or attempt to disconnect
any components of this water heater without positively assuring that the water is cool and has no pressure. Always wear
protective clothing and equipment when installing, starting up or servicing this water heater to prevent scalding injuries.
Do not rely on the pressure and temperature gauges to determine the temperature and pressure of the water heater.
This water heater contains components that become very hot when the boiler is operating. Do not touch any components
unless they are cool.
Failure to follow all instructions in the proper order can cause personal injury or death. Read all instructions, including all
those contained in component manufacturers’ manuals before installing, starting up, operating, maintaining, or servicing
the water heater.
! CAUTION
To reduce the risk of excessive pressures and temperatures in this water heater, install temperature and pressure
protective equipment required by local codes but no less than a combination temperature relief valve certified by a
nationally recognized testing laboratory that maintains periodic inspection of production of listed equipment or materials,
as meeting the requirements for Relief Valves and Automatic Shutoff Devices for Hot Water Supply Systems, ANSI Z21.22latest edition. This valve must be marked with a maximum set pressure not to exceed the marked working pressure of
the water heater. Install the valve into an opening provide and marked for this purpose in the water heater, and orient it
or provide tubing so that any discharge from the valve will exit only within 6 inches above, or at any distance below, the
structural floor, and cannot contact any live electrical part. The discharge opening must not be blocked or reduced in size
under any circumstances.
These water heaters with single-wall stainless steel heat exchangers meet the Uniform Plumbing Code for installation in
potable water systems provided that:
•The boiler water, including additives, is practically non-toxic, having a toxicity rating of class 1 as listed in Clinical
Toxicology of Commercial Products, latest edition.
•The boiler water pressure is limited to maximum 30 psig by an approved safety or relief valve.
•The heat transfer medium is potable water or contains only substances that are recognized as safe by the U.S. Food
and Drug Administration. (FDA)
•The pressure of the heat transfer medium is maintained less than the normal minimum operating pressure of the
potable water system.
The maximum boiler water supply temperature to the indirect heat exchanger must not exceed 240 deg. F (115 deg. C).
Improper water quality will reduce the life of the water heater. Hard water, sediment, high or low PH and high levels of
chlorides in the domestic water should be avoided. Be sure that PH levels fall between 6 and 8 and dissolved chlorides
are less than 100 ppm. A filter must be used where sediment is greater than 5 microns in size in the water supplied to
the unit. A water softening system is recommended for areas with hard water. In cases where water quality is unknown, a
qualified water treatment expert should be consulted.
NOTICE: Damage to tanks caused by improper water quality is not covered under the warranty.
3
! DANGER
DO NOT store or use gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
If you smell gas vapors, DO NOT try to operate any appliance - DO NOT touch any electrical switch or use any phone in
the building. Immediately, call the gas supplier from a remote located phone. Follow the gas supplier’s instructions or if
the supplier is unavailable, contact the fire department.
! DANGER
This water heater is supplied with an adjustable thermostat to control the water temperature. Hot water temperatures
required for automatic dishwashers and laundry use can cause scald burns resulting in serious personal injury and/or
death. The temperature at which injury occurs varies with the person’s age and the time of exposure. The slower response
time of disabled persons increases the hazard to them. NEVER allow small children to use a hot water tap or to draw their
own bath water. NEVER leave a child or disabled person unattended in a bathtub or a shower.increases the hazard to
them. NEVER allow small children to use a hot water tap or to draw their own bath water. NEVER leave a child or disabled
person unattended in a bathtub or a shower.
II. IMPORTANT SAFETY INSTRUCTIONS
! WARNING
– When using electrical appliances, basic safety precautions to reduce the risk of fire, electric shock, or injury to persons should be followed, including:
READ ALL INSTRUCTIONS BEFORE USING THIS INDIRECT WATER HEATER.
1. Install or locate this water heater only in accordance with the provided installation instructions
2. Use this water heater only for its intended use as described in this manual.
3. As with any appliance, close supervision is necessary when used by children.
4. Do not operate this water heater, if it is not working properly, or if it has been damaged or dropped.
5. This water heater should be serviced only by qualified personnel. Contact nearest authorized service facility for
examination, repair, or adjustment.
4
II. Pre-installation Considerations
Inspect shipment carefully for signs of damage. All equipment is carefully inspected and packed. Manufacturer’s
responsibility ceases upon delivery of the water heater to the carrier in good condition. Any claims for damage or
shortage, must be filed immediately against the carrier by the consignee. No claims for variances or shortages will be
allowed by the Manufacturer, unless they are presented within sixty days after receipt of the equipment.
Installation must conform to the requirements of the authority having jurisdiction. In the absence of such requirements,
installation must conform to the National Plumbing Code and the National Electrical Code ANSI/NFPA No. 70, current
edition.
IMPORTANT CONSIDERATIONS BEFORE INSTALLATION
1. Water Heater Sizing.
Choose the water heater model based on the expected water usage for the given site. The average residence
with one shower or more will require a Model 40 or larger. The Model 30 should only be considered for
residences with minimal water demand, or for commercial applications without showers. See Tables 2 and 3.
Consult ASHRAE sizing guides and other references.
Factors that increase water demand dramatically include high flow shower heads, hot tubs, and the use of more than one
shower at a time. Increase the tank size if these factors are present. Consult ASHRAE sizing guides and other references.
Dimensions, weights, ratings, and capacities are outlined in Table 1.
2. Boiler Sizing.
The water heater will provide the rated performance only if it is used with a boiler with a heating capacity of at least as
much as the capacity ratings in Tables 2 and 3. If the boiler has less capacity, the water heating output will be reduced.
NOTICE
If the boiler takes longer to heat up from a cold start, hot water shortage may occur.
The maximum heat transfers through the coil (heat input) of the water heaters at 240 deg.
F boiler supply temperature and 210 deg. F potable water temperature are as follows:
•Models 30 – 115 single coil units and models 60-D, 80-D, and 115-D dual coil units
are less than 96,000 BTU/HR.
•Models 80-HO, 115-HO, 80-HO-C, and 115-HO-C high output units are less than
84,000 BTU/HR.
•Models 85-XHO and 115-XHO, the extra high output series, are less than 175,000
BTU/HR.
Potable water temperature is limited to below 210 deg. F and nominal water containing
capacity is below 120 gallons for all indirect models.
Accordingly, per Part HLW-101.2, Section IV of the ASME Boiler and Pressure Vessel Code,
all indirect water heater products are exempt from compliance with the code.
Check with local codes for applicability
5
STANDARD AND HO UNITS
HOC UNITS
6
XHOC EXTRA HIGH OUTPUT UNITS
XHOC HIGH OUTPUT INDIRECTS
MODEL 115-XHOC - HEIGHT = 74" - 115 GAL.
MODEL 85-XHOC - HEIGHT = 64" - 86 GAL.
COLD AND HOT DOMESTIC - 1 ½" NPT CONNECTIONS
COIL SUPPLY AND RETURN - 1 ½" NPT CONNECTIONS
TABLE 1- Dimensions and Capacities
Storage
Volume
Coil
Heating
Surface
Gals.
Sq. Ft.
Ht.
Dia.
Domestic
Water
In/Out
H2OI30
30
7.3
34.0
23.5
H2OI40
40
7.7
44.0
23.5
Model
Dimensions
(Inches)
Max. Tank
Working
Pressure
Max. Coil
Working
Pressure
Approx.
shipping
Wt.
Boiler
Water
In/Out
(psi)
(psi)
Lbs.
3/4
1
150
90
85
3/4
1
150
90
100
Piping Connections
N.P.T
H2OI40L
42
7.4
36.0
28.0
3/4
1
150
90
100
H2OI50
50
8.2
54.0
23.5
3/4
1
150
90
110
H20I60
60
8.6
62.0
23.5
3/4
1
150
90
125
H2OI60L
60
7.7
46.0
28.0
3/4
1
150
90
120
H2OI80
80
8.2
56.0
28.0
1
1
150
90
140
H2OI115
115
9.1
74.0
28.0
1
1
150
90
175
High Output Units
H2OI60HO
60
15.1
62.0
23.5
1
1
150
90
145
H2OI80HO
80
14.8
56.0
28.0
1
1
150
90
155
H2OI8H0C
80
14.8
56.0
28.0
1½
1¼
150
90
155
H2OI115HO
115
15.6
74.0
28.0
1
1
150
90
190
H2OI115HOC
115
15.6
74.0
28.0
1½
1¼
150
90
190
Extra High Output Units 85-XHO and 115-XHO
H20I85XHOC
87
28.7
64.0
28.0
1½
1½
150
90
215
H20I115XHOC
115
28.7
74.0
28.0
1½
1½
150
90
240
7
Table 2 - 200 deg F Boiler Supply Ratings
Model
Max. First
Hour Rating
Continuous
Rating
Gal/Hr. @
Gal/Hr @
140 F
115 F
140 F
Boiler Output
Needed
Boiler Water
Flow Through
Coil
Pressure
Drop
Through Coil
(BTU/Hr)
Gal/Min
(Ft. Water)
115 F
H20I30
202
269
175
242
131,250
14.0
5.3
H2OI40
221
292
185
256
138,670
14.0
5.7
H2OI40L
212
251
176
215
132,000
14.0
5.3
H2OI50
223
291
178
246
133,280
14.0
6.0
H20I60
262
342
208
288
155,700
14.0
6.2
H20I60L
239
310
185
256
138,570
14.0
5.7
H2OI80
271
248
199
276
149,390
14.0
6.0
H2OI115
324
409
221
306
165,750
14.0
6.6
263,600
14.0
10.1
High Output Units 60-HO, 80-HO, and 15-HO
H2OI60HO
406
541
352
478
H2OI80HO
418
551
346
479
259,340
14.0
9.9
H2OI80HOC
442
584
370
512
277,070
21.0
10.5
H2OI15HO
467
607
364
504
273,100
14.0
15.8
H2OI115HOC
479
623
376
520
281,800
21.0
16.7
Extra High Output Units 85-XHO and 115-XHO
H2OI85XHOC
738
992
660
914
495,000
28.0
13.0
H2OI115XHOC
763
1017
660
914
495,000
28.0
13.0
Table 3 - 180 deg F Boiler Supply Ratings
Model
Max. First
Hour Rating
Gal/Hr. @
Continuous
Rating
Boiler Output
Needed
Boiler Water
Flow Through
Coil
Pressure
Drop
Through Coil
(BTU/Hr)
Gal/Min
(Ft. Water)
Gal/Hr @
140 F
115 F
140 F
115 F
H20I30
176
233
149
206
111,560
14.0
5.3
H2OI40
193
254
157
218
117,870
14.0
5.7
H2OI40L
186
251
150
215
223,300
14.0
5.3
H2OI50
196
254
151
209
113,290
14.0
6.0
H20I60
231
298
177
244
132,340
14.0
6.2
H20I60L
211
272
157
218
117,785
14.0
5.7
H2OI80
241
306
169
234
126,980
14.0
6.0
H2OI115
291
363
188
260
140,890
14.0
6.6
High Output Units 60-HO, 80-HO, and 15-HO
H2OI60HO
353
468
299
414
224,200
14.0
10.1
H2OI80HO
366
479
294
407
220,440
14.0
9.9
H2OI80HOC
386
507
314
435
235,510
21.0
10.5
H2OI15HO
413
532
310
429
232,135
14.0
15.8
H2OI115HOC
423
545
320
442
239,530
21.0
16.7
Extra High Output Units 85-XHO and 115-XHO
H2OI85XHOC
649
868
571
790
428,000
28.0
13.0
H2OI115XHOC
674
893
571
790
428,000
28.0
13.0
NOTE: All ratings are based on 50 deg. F cold water inlet.
8
3. Circulator Sizing.
Refer to Tables 2 and 3 for the minimum flow through the water heater coil and the pressure drop at minimum flow.
Calculate the pressure drop across all piping and fittings connected to the water heater zone. Be sure to include all zone
valves, check valves, and shut-off valves. It is recommended that the water heater zone be piped with 1” pipe around the
entire loop on typical residential sites.
A. System Zone Control
The water heater must be installed as a separate zone from the space heating system. The water heating zone’s piping
and circulator must be sized for the minimum flow rate with all the zones in use and a maximum flow with only the water
heater in use. Best performance is normally achieved using zone control with circulators.
The three most common systems are:
1.
2.
3.
Zone Circulators- Space heating zones use a circulator for each zone. The water heater is controlled with an
additional circulator.
Hybrid System- Space heating zones use zone valves for each zone. The water heater is controlled with an
additional circulator.
Zone Valves – Space heating zones use zone valves for each zone. The water heater is controlled with an
additional zone valve. Select a valve with a low pressure drop, and assure minimum flow with adequate pipe
sizing.
B. Priority or Non-Priority for Hot Water
1. Option 1 – Priority. The demand for space heating is interrupted until the hot water demand is satisfied. This
option provides the maximum delivery of hot water.
Priority is recommended when:
A. The boiler output is less than 100,000 Btu per hour, or
B. The boiler output required to satisfy the hot water demand is more than 50% of the boiler output needed to
satisfy the space heating demand, or
C. When an interruption in space heating can be tolerated during long domestic hot water draws.
In most cases the delay in space heating will not be noticed because of the rapid recovery of the water
heater. It must be recognized however that certain water heater malfunctions, such as a failed thermostat or
circulator, could delay space heating indefinitely.
2. Option 2 – Non-Priority. The boiler output is divided between space heating and water heating. Heating of
domestic hot water can be reduced during simultaneous space and water heating demands. The amount of
reduction depends on the boiler output, the number of space heating zones calling, and the amount of boiler
water flow split between the space heating and zones and the water heater zone.
9
C.
Locating the water heater.
Water heater should be located in an area where water leakage from the tank or connections will not result in damage to
areas adjacent to the water heater or to lower floors of the structure. When such a location can not be avoided, a suitable
drain pan must be installed under the water heater, and the drain pan must be connected to a drain.
Water heater should be installed as close to the boiler as is practical for easy access for service. Unit is designed for
installation on combustible flooring and in alcoves, closets, etc.
The minimum clearances from combustible surfaces are:
Bottom-------------------------0”
Left, right, and rear sides -- 1”
Front---------------------------1”
Top-----------------------------6”
The minimum clearances for service are:
1”
1”
1”
1”
1”
Bottom-------------------------0”
Left, right, and rear sides -- 3”
Front--------------------------30”
Top-----------------------------6”
D.
1. 2.
3.
4.
5.
6.
E.
Additional components
Front View
Top View
Shut-off valves. Allows the isolation of the water heater from the boiler system during service.
Unions. Allows for easy locating or removal. Use dielectric unions or couplings to protect hot and cold water
fittings from corrosion when connecting dissimilar materials such as copper and galvanized pipe.
Vacuum breaker. Protects the water heater from collapse if a hot tank is valved off to service other components
in the system. Required for Commonwealth of Massachusetts.
Thermal expansion tank. If the water heater is installed in a closed water supply system, such as a system
having a back flow preventer in the cold water supply line, the installation of a thermal expansion tank is
required.
Water hammer arrester. Dishwashers, clothes washers, and fast-closing positive shutoff valves incorporated
in the system all contribute to creating water hammer. Install a water hammer arrester to prevent damage to
pipes and appliances. See control manufacturer's instructions for application and installation.
Backflow preventer. Protects potable water supplies from contamination due to backflow. Required for
Commonwealth of Massachusetts.
Removing the Existing Domestic Water Heating System
External Tankless Heater- Disconnect all lines to the boiler and plug the boiler fittings. Disconnect the external
heater from the boiler piping, and the domestic piping systems.
2. Internal Tankless Heaters- Disconnect the domestic piping. Do not plug the cold water or the hot water fittings
in the internal tankless coil. Leave the coil in the boiler with the cold and hot water fittings open to prevent
pressure build-up in the coil.
1.
NOTICE
For California installation this water heater must be braced, anchored, or stapped to avoid falling or
moving during an eathquake. See instructions for correct installation procedures. Instructions may
be obtained from California Office of the State Architect.
10
F.
Water Quality
Improper water quality will reduce the expected life of the water heater. Hard water, sediment, high or low Ph, and high
levels of chlorides in the domestic water should be avoided. Sediment and hard water will eventually coat the heating coil
inside the water heater and reduce the rate of hot water production and may, eventually cause a failure. High or low Ph
and/or high chloride concentrations will cause corrosion and eventually failure. A filter is strongly recommended where
sediment is present in the water. A water softening system is recommended for areas with hard water.
In an area where the water quality is not known, a water quality test should be performed.
WARNING:
Do not operate the water heaters in areas where the Ph is above 8.0 or below 6.0, and/or with chloride concentrations
greater than 100 parts per million (ppm). ECR’s standard warranty does not cover problems caused by improper water Ph
or excessive levels of chlorides.
NOTICE
Damage to tanks caused by improper water quality is not covered under the warranty.
III. Piping
A. Domestic water piping. See Figure 1.
1. Shut off the cold water supply at the main shutoff valve.
Open one or more faucets to relieve the pressure. Open the system drain, leaving the faucets open.
Drain the domestic water system.
2. Position the water heater in the final location.
3. Connect the cold water supply piping.
•Install piping onto cold inlet connection.
•Connect to cold water supply connection using a union, a heat trap, a shut-off valve, a vacuum breaker, an
expansion tank (where required), and a filter (recommended to prevent sediment buildup).
NOTICE
If installing on a city supply, a properly sized thermal expansion tank is required and should be installed in
accordance with the product installation manual.
If a water heater is installed in a closed water supply system, such as one having a backflow preventer in the cold
water supply, a check valve in the cold water supply, or a pressure reducing valve in the cold water supply means
shall be provided to control thermal expansion.
The appliance, when installed, must be grounded in accordance with the local codes, or in the absence of local
codes, with the National Electrical Code, ANSI/NFPA 70.
WARNING
If this product is connected to a cold water supply line that has a check valve, a backflow preventer, a pressure
reducing valve, or a check valve in the water meter, it is a requirement that a properly sized thermal expansion
tank be installed in the cold water inlet line. There will be no warranty on applications where there is no pressure
control.
4.
Connect the domestic hot water piping.
Install piping on to hot water supply connection using a union, a heat trap, a vacuum breaker, and a shut-off valve.
11
5.
Pipe the relief valve discharge so that the discharge from the valve will exit only within 6 inches above, or at
any distance below, the structural floor, and cannot contact any live electrical part. The discharge opening must not be blocked or reduced in size under any circumstances.
WARNING
Install a discharge line so that water discharged from the temperature and pressure relief valve will exit within
six (6) inches above, or any distance below, the structural floor and cannot contact any live electrical part. The
discharge line is to be installed to allow for complete drainage of both the temperature and pressure relief valve
and the discharge line. The discharge opening must not be subjected to blockage or freezing.
DO NOT thread, plug, or cap the discharge line. It is recommended that a minimum clearance of four (4) inches
be provided on the side of the water heater for servicing and maintenance of the combination temperature and
pressure relief valve.
Do not place a valve between the combination temperature and pressure relief valve and the tank!
6.
B.
Fill the water heater tank.
Open all faucets to allow air to purge from the tank and piping. Remove screens on faucets.
Open domestic hot water shut-off valve.
Open cold water inlet shut-off valve.
Purge all of the air from the domestic water system. Allow water to run so the tank is completely purged of any
debris. Run the water long enough to change at least five tank volume changes. Close all faucets. Reinstall all of
the screens in the faucets.
Check the system for leaks. Repair as required.
Water boiler piping. See Figures 3 and 4.
1.
2.
Determine where the boiler, the space heating, and the water heater connections should be made based on the
type of piping system that is either in place, or is to be installed for a new hydronic system installation. See
Figure 3, Boiler Water Piping with Zone Circulators, and Figure 4, Boiler Water Piping with Zone Valves.
It is recommended that 1” pipe and 1” zone valves be used on the water heater zone on residential site and 1¼"
and 1½" pipe be used on High Output units on commerical sites.
Zone Circulator System
For space heating systems that use Zone Circulators, refer to Figure 3. The water heater connection labeled
“BOILER SUPPLY” should be piped to the boiler supply piping after the air purger and before the space heating
takeoffs. Mount the water heater circulator as close as possible to the water heater, and make sure the flow
arrow points toward the water heater. The use of shut-off valves is recommended for future service convenience.
The water heater connection labeled “BOILER RETURN” should be piped to the boiler return piping as close to
the boiler as possible and after any flow control or check valves in the space heating return piping. The use of a
union and a shut-off valve is recommended. The use of a check valve is required to prevent back flow through
the water heater during operation of the space heating system.
Zone Valve System
For a space heating system that uses Zone Valves, refer to Figure 4. The water heater connection labeled
“BOILER SUPPLY” should be piped to the boiler supply piping after the air purger and before the space heating
circulator. Mount the water heater circulator as close as possible to the water heater, and make sure the
flow arrow points toward the water heater. The use of a shut-off valve is recommended for future service
convenience.
The water heater connection labeled “BOILER RETURN” should be piped to the boiler return piping as close to
the boiler as possible and after any flow control or check valves in the space heating return piping. The use of a
union and a shut-off valve is recommended. The use of a check valve is required to prevent back flow through
the water heater during operation of the space heating system.
12
NOTICE
Figures 1, 2, 3 and 4 are meant to illustrate system piping only. The Installer is responsible for
conforming to the Local Codes. In Massachusetts, you must install a vacuum relief valve per 248 CMR.
See local code requirements.
Figure 1 - Domestic Water Piping
Pipe relief valve discharge to
within 6" of floor. See Section
III, item #5.
Figure 2 - Typical Mixing Valve Install
Shut off
Valve
Check
Valve
Cold Water Supply
Cold
Inlet
Expansion
Tank
Pipe relief valve discharge
to within 6" of floor. See
Section III, item #5.
Hot
Outlet
Solar
Water
Heater
with
boiler
indirect
or
electric
back up
Single Tank
Installation
13
Antiscald
valve
Temperature
& Pressure
Relief Valve
Drain Valve
Hot Water Supply
Figure 3 - Boiler Water Piping with Zone Circulators
Pipe relief valve discharge
to within 6" of floor. See
Section III, item #5.
Figure 4 - Boiler Water Piping with Zone Valves
Pipe relief valve discharge
to within 6" of floor. See
Section III, item #5.
14
IV. Electrical
1.
2.
3.
Install electric wiring and grounding in accordance with the National Electrical code and local regulations.
All water heaters are supplied with a thermostat.
Refer to schematics for separate circulator wiring.
Refer to schematics for zone valve wiring.
Reference should be made to the Installation Manual for the boiler as well.
V. Operation
Startup
After the water heater has been plumbed and wired, and the boiler water piping is purged of air, the water heater is ready
to be started.
1. Follow the boiler installation instructions to place the boiler in operation.
2. The tank thermostat is factory pre-set to 125 degrees F and will call for heat if the water in the tank is lower
than 125.
3. On a call for heat, the tank thermostat contacts close to start the water heater zone circulator and the boiler.
4. After the tank has reached the temperature setting, the tank thermostat opens and de-energizes the circulator
and the boiler. If there is a call for space heating, the boiler will continue to run until the room thermostats are
satisfied.
WARNING
This water heater can deliver scalding temperature water at any faucet in the system. Be careful when
using hot water to avoid scalding injury. By setting the thermostat on this water heater to obtain an
increased water temperature, you create the potential for scald injury. To protect against injury, you
should install an ASSE approved mixing valve ( a device to limit the temperature of water to protect
against scald injury via mixing hot and cold water supply) in the water system. This valve will reduce
point of discharge temperature in branch supply lines. Such valves are available from a local plumbing
supplier. Please consult with a plumbing professional.
15
Temperature Adjustment
The tank thermostat controls the maximum water temperature in the water
heater. If it is set too high, the resulting hot water can cause painful scalding
with possible serious and permanent injury. The temperature at which this
occurs varies with a person’s age, and the length of time in contact with the
hot water. The slower response time of infants, older, or handicapped people
increases the hazard for them.
It is recommended that the thermostat be set for the lowest possible
temperature that satisfies your needs. This will also provide you with the
lowest energy consumption and cost.
Check the water temperature at a hot water faucet soon after the tank
thermostat has satisfied, and the circulator and the boiler have turned off.
Adjust as needed.
Lowering the thermostat setting will not have an immediate effect on the
water temperature because the stored water will have to be used and the
thermostat must go through the cycle of heating cold water and satisfying at
the new, lower temperature. Additional temperature checks should follow the
completion of a heating cycle. Further adjustments may be required after you
have used the water heater.
The table below details the approximate relationship of water
temperature and time with regard to scald injury and may be used
as a guide in determining the safest water temperature for your
applications.
Approximate Time/Temperature
Relationships in Scalds
120°F (52°C)
More than 5 Minutes
125°F (52°C)
1½ to 2 Minutes
130°F (54°C)
About 30 Seconds
135°F (57°C)
About 10 Seconds
140°F (60°C)
Less Than 5 Seconds
145°F (63°C)
Less Than 3 Seconds
150°F (66°C)
About 1½ Seconds
155°F (68°C)
About 1 Second
The scald label show to the right can be found on all Indirect
Water Heaters and Storage tanks. Take note and use caution when
adjusting the temperature settings with your water system. Be sure
to always feel the water before bathing or showering, especially
when drawing a bath for an infant or elder.
Hot Water Can Scald!
Water heated to temperature for
clothes washing, dish washing and
other sanitizing needs can scald
and cause permanent injury.
Children, elderly, and infirm or
physically handicapped persons
are more likely to be permanently
injured by hot water. Never leave
them unattended in bathtub or
shower. Never allow small children
to use a hot watertap or draw their
own bath.
If anyone using hot water in the
building fits the above description,
or if state laws or local codes
require certain water temperatures
at hot water taps, you must take
special precautions:
• Use lowest possible temperature
setting.
• Install some type of tempering
device, such as an automatic
mixing valve, at hot water tap
or water heater. Automatic
mixing valve must be selected
and installed according to
manufacturer's recommendations
and instructions.
Water passing out of drain valves
may be extremely hot. To avoid
injury:
• Make sure all connections are
tight.
• Direct water flow away from any
person.
16
WARNING
It is the responsibility of the installing contractor to see that all controls are correctly installed and are
operating properly when the installation is complete.
DO NOT operate the water heater with jumpered or absent controls or safety devices.
DO NOT tamper with or alter the water heater and /or controls.
DO NOT operate the water heater if any external part has been under water. Immediately call a
qualified service technician to inspect the appliance and to replace any part of the control system that
is or had been under water.
DO NOT install this water heater on carpeting. This water heater is suitable for installation on
combustible flooring.
DO NOT operate this water heater without first being certain it is filled with water.
17
Argo offers a broad line of controls for water heating and multiple zone boiler heating applications.
Please check out our web site at http://www.argoindustries.com for applications information and comprehensive wiring
diagrams.
A typical wiring diagram is shown below. This is a multi-zone application using zone pumps with programmable domestic
hot water priority using our ARM-4P Panel.
Product features include:
1. Built in transformer that will support up to 15 zones. Transformer has electronic fuse protection to prevent
transformer overloading.
2. Data Port Terminal for easy connection to other Argo control products.
3. Expansion module plug-in allowing easy expansion to more zones.
4. Priority Zone Safety Timer. If the priority zone calls for more than 30 minutes the priority zone feature will turn
off allowing all zones to operate independently preventing freeze ups if water heater has a problem.
5. Plug in replacement relays for long life and easy servicing with 1/3 HP pump motor ratings.
INDIRECT WATER TANK TO ARM-4P CONTROL
Class 2
Terminals
To Boiler T-T
Terminals
Primary
Terminals
18
19
VI. Maintenance
The water heater is intended to provide many years of reliable service. Components, such as thermostats and relief
valves, may be subject to failures that require service. Depending on the quality of the water supply, sediment and/or
scale may coat the heating coil in the tank and reduce hot water recovery rate. Failure to use the correct procedures or
parts can result in unsafe operation.
The owner should arrange to have the following inspections and simple maintenance procedures done at the suggested
frequencies.
1.
2.
Boiler and Domestic Water Piping (Annual)
Check all piping for signs of leakage at the joints, unions and shut-off valves. Repair as required.
Temperature and Pressure Relief Valve (Annual)
•The temperature and pressure relief valve should be checked to ensure that it is in operating condition. To
check the relief valve, lift the lever at the end of the valve several times. The valve should seat properly and
operate freely. If water does not flow, remove and inspect for obstructions or corrosion. Replace with a new
valve of the recommended capacity as necessary. Do not attempt to repair the valve, as this could result in
improper operation and a tank explosion. In areas with poor water conditions, it may be necessary to inspect
the temperature and pressure relief valve more often than once a year.
CAUTION
Before manually operating the valve, make sure that a drain line has been attached to the valve to direct the
discharge to an open drain. Failure to take this precaution could mean contact with extremely hot water discharging
from the valve during this checking operation.
If the temperature and pressure relief valve on the heater discharges periodically or continuously, it may be due
to thermal expansion of water in a closed water supply system, or it may be due to a faulty relief valve. Thermal
expansion is the normal response of water when it is heated. In a closed system, thermal expansion will cause the
system pressure to build until the relief valve actuation pressure is equaled. Then the relief valve will open, allowing
some water to escape, slightly lowering the pressure. Contact your water supplier or local plumbing inspector on
how to control this situation.
3.
4.
Sediment (Annual except where harsh water quality may require more frequent service)
Depending on water conditions, a varying amount of sediment may collect in the tank. Levels requiring service
are indicated by a small temperature difference between the boiler supply and return lines, and a reduced
recovery rate. Repeated flushing usually clears such material. As a preventive measure, water should be drawn
from the drain valve until it runs clear and the installation of a water filter should be considered.
Scale (Annual)
Hard water may cause scale buildup on the outside of the heating coil inside the tank. A water softener will
prevent this problem. Symptoms are identical to sediment buildup. If repeated flushing does not resolve the
problem, chemical cleaning may be required. Contact a qualified contractor.
20
5. Inspect Anode (annual)
•The purpose of the magnesium anode is to reduce the damaging effects of aggressive water on the water
heater. Aggressive water will cause the anode(s) to erode. The anode(s) must be inspected at least annually
to determine whether a new anode should be installed. Use anode replacement parts supplied by ECR only.
ECR anodes are 1-1/4 NPT and are made with magnesium, brass, and stainless steel. There is no steel in a
ECR anode. Severe or rapid deterioration of the anode indicates very aggressive water. If this occurs, have
the water tested to verify whether it is within the limits outlined on page 11. Failure to inspect the anode
regularly and replace if necessary could result in damage to the water heater. If this unit is installed and
maintained according to the instructions and conditions in this manual, this product will last for a long time.
1. Close domestic water isolation valves.
2. Drain the water heater completely and allow it to cool off.
3. Remove the anode cover on the front of the unit. See figures on pages 6 and 7. The temperature control
4.
5.
6.
7.
8.
can be turned to the side to allow easier access.
After the water heater has drained and cooled, remove the anode using a 1¾” 6-point socket and a
breaker bar.
Inspect the anode and replace if needed. The anode should be replaced when more than 6” of core wire is
exposed. The anode should be replaced with a ECR supplied anode only. See above. The brass hex on the
anode is 1¼ NPT and installs into a 1¼ stainless half coupling on the shell of the tank. This part will need
to be properly Teflon taped and coated with a quality Teflon based pipe sealant.
Replace the inspection cover.
Refill the water heater, and restore to operation.
Verify operation of boiler and water heater.
21
VII. Troubleshooting
PROBLEM
CAUSE
Boiler does not operate.
No hot water at faucets
Insufficient or runs out of hot water
at the faucet
Water at faucet too hot
Boiler cycles more than 5 times per
day in summer
SOLUTION
Press reset button
Check main cut-off switch
Check fuses or breakers.
Check power supply
Check shaft coupling
Circulator does not operate
Check shaft coupling
Improper thermostat setting
Turn thermostat to a higher setting.
Zone valve does not open
Check power supply and valve
Electrical problem
Check fuses and replace.
Check circuit breaker and reset.
Check power supply
Sediment and/or scale buildup
If boiler, circulator, and thermostat are
operating properly, and the boiler is cycling
on the high limit several times before the
tank thermostat is satisfied, the coil may
have a coating of sediment and/or scale.
Clogged filter
Clean or replace filter.
Thermostat setting too low.
Turn the thermostat to a higher setting.
Undersized boiler with no priority to
domestic water heating.
Rewire for priority.
Peak draw of hot water is greater than
the tank storage.
Determine peak usage and compare to tank
volume.
Sediment and/or scale buildup
Clean coil
Faulty water heater thermostat
Replace thermostat
Thermostat set to high
Lower thermostat setting.
Improper system plumbing
Compare plumbing to installation guide.
Inspect check valves.
Improper wiring.
Compare wiring to installation guide.
Excessive demand
Reduce demand or consider larger boiler
and/or water heater.
Faulty thermostat
Replace thermostat
Boiler high limit set to low
Increase boiler hi-limit setting
Sediment and or scale buildup
Clean coil.
22
REPLACEMENT PARTS LIST
Description
Part Number
1
Temperature and Pressure Relief Valve
(for all models except XHOC)
240010926
2
Temperature and Pressure Relief Valve
(for XHOC models only)
240010927
3
Aquastat Well, Stainless Steel
240009522
4
Aquastat
240009521
5
Drain Valve Nipple, ½" x 3½" Stainless Steel
240010930
6
Drain Valve
240010928
7
Anode Rod
240010929
XHOC HIGH OUTPUT INDIRECTS
STANDARD AND HO UNITS
HO-C UNITS
23
24
25
NOTES
26
NOTES
27
H2O
ECR International, Inc
2201 Dwyer Avenue, Utica NY 13504-4729
web site: www.ecrinternational.com